Ram B1500, B2500, B3500, 1999-2003

Relieving Fuel System Pressure

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel tank filler cap to release any fuel tank pressure.
  6.  
  7. Unscrew the plastic cap from the pressure test port on the fuel rail. On the 8.0L engine, the test port is found at the front of the engine.

    Click image to see an enlarged view

    Fig. Fuel pressure test port-3.9L engine



    Click image to see an enlarged view

    Fig. Fuel pressure test port-5.2L engine, 5.9L engine is similar

  8.  
  9. Obtain a fuel pressure gauge/hose from a Fuel Pressure Gauge tool set No. 5069, or equivalent. Remove the gauge, then place the gauge end of the hose into a suitable gasoline container.
  10.  
  11. Place a shop towel under the test port.
  12.  
  13. Screw the other end of the hose onto the fuel pressure port to relieve the pressure.
  14.  
  15. When the pressure has been relieved, remove the hose and cap the port.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel tank filler cap to release any fuel tank pressure.
  6.  
  7. Remove the fuel pump relay from the PDC.
  8.  
  9. Start and run the engine until it stops.
  10.  
  11. Unplug the connector from any injector and connect a jumper wire from either injector terminal to the positive battery terminal. Connect another jumper wire to the other terminal and momentarily touch the other end to the negative battery terminal.
    WARNING
    Just touch the jumper to the battery. Powering the injector for more than a few seconds will permanently damage it.

  12.  
  13. Place a rag below the quick-disconnect coupling at the fuel rail and disconnect it.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel tank filler cap to release any fuel tank pressure.
  6.  
  7. Unscrew the plastic cap from the pressure test port on the fuel rail.

    Click image to see an enlarged view

    Fig. Fuel pressure test port-3.9L engine



    Click image to see an enlarged view

    Fig. Fuel pressure test port-5.2L engine, 5.9L engine is similar

  8.  
  9. Obtain a fuel pressure gauge/hose from a Fuel Pressure Gauge tool set No. 5069, or equivalent. Remove the gauge, then place the gauge end of the hose into a suitable gasoline container.
  10.  
  11. Place a shop towel under the test port.
  12.  
  13. Screw the other end of the hose onto the fuel pressure port to relieve the pressure.
  14.  
  15. When the pressure has been relieved, remove the hose and cap the port.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel tank filler cap to release any fuel tank pressure.
  6.  
  7. Remove the fuel pump relay from the PDC.
  8.  
  9. Start and run the engine until it stops.
  10.  
  11. Unplug the connector from any injector and connect a jumper wire from either injector terminal to the positive battery terminal. Connect another jumper wire to the other terminal and momentarily touch the other end to the negative battery terminal.
    WARNING
    Just touch the jumper to the battery. Powering the injector for more than a few seconds will permanently damage it.

  12.  
  13. Place a rag below the quick-disconnect coupling at the fuel rail and disconnect it.
  14.  


CAUTION
The fuel injection system is under constant pressure (up to approximately 50 psi). Before servicing any part of the fuel injection system, the pressure must be released. Observe all applicable and common sense safety precautions during these procedures.

The system may or may not be fitted with a pressure test port. Check first, and then follow the appropriate procedure.


CAUTION
Whenever servicing the fuel system, always work in a well ventilated area. Do NOT allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Fuel system work is made more hazardous by a hot engine. Work on a cold engine whenever possible.

 
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